TM 9-6115-641-24Title TM 9-6115-641-24 Author US Army Subject Unit, Direct & General Support for...

ARMY TM 9-6115-641-24AIR FORCE TO 35C2-3-456-12

TECHNICAL MANUALUNIT, DIRECT SUPPORT AND

GENERAL SUPPORT MAINTENANCEMANUAL

GENERATOR SET,SKID MOUNTED, TACTICAL QUIET

5 KW, 60 AND 400 Hz

MEP-802A (60 Hz) 6115-01-274-7387MEP-812A (400 Hz) 6115-01-274-7391

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY ANDTHE AIR FORCE

1 SEPTEMBER 1993

CHANGE 4This change was not available from the proponent or the Publication Distribution Center at the time of the CD release.Please refer to your paper or microfiche copy as appropriate.

NOT DIGITIZED

CHANGE

No.3


C3

HEADQUARTERS. DEPARTMENTS OFTHE ARMY AND THE AIR FORCE

WASHINGTON, DC., 30 September 1995

UNIT, DIRECT SUPPORT ANDGENERAL SUPPORT MAINTENANCE MANUAL


5KW, 60 AND 400 HzMEP-802A (60Hz) 6115-01-274-7387MEP-812A (400Hz) 6115-01-274-7391

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TM 9-6115-641-24/TO 35C2-3-456-12,1 September 1993, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical barin the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages1-19 and 1-20 1-19 and 1-20

2-53 through 2-56 2-53 through 2-56

2-71 and 2-72 2-71 and 2-72

2-125 through 2-128 2-125 through 2-128

2-135 and 2-136 2-135 and 2-136C-1 and C-2 C-1 and C-2

2. Retain this sheet in front of manual for reference purposes.


C3

By Order of the Secretaries of the Army and Air Force:

Official:

YVONNE M. HARRISONAdministrative Assistant to the

Secretary of the Army00954

DENNIS J. REIMERGeneral, United States Army

Chief of Staff

RONALD R. FOGELMANGeneral, USAFChief of Staff

HENRY VICCELLIO, JR.General, USAFCommander, Air Force Materiel Command

DISTRIBUTION:To be distributed in accordance with DA Form 12-25-E, block no. 5242, requirements for

TM 9-6115-641-24.

CHANGE

NO. 2


C2

HEADQUARTERS, DEPARTMENTS OFTHE ARMY AND THE AIR FORCEWASHINGTON, D.C., 30 APRIL 1995

Unit, Direct Support andGeneral Support Maintenance Manual


5KW, 60 AND 400 HzMEP-802A (60Hz) 6115-01-274-7387

MEP-812A (400Hz) 6115-01-274-7391

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TM 9-6115-641-24/TO 35C2-3-456-12, 1 September 1993, is changed as follows:


Remove pages

1-5 and 1-61-13 and 1-142-33 and 342-57 and 2-582-65 and 2-662-105 and 2-1062-123 and 2-124

Insert pages

1-5 and 1-61-13 and 1-142-33 and 2-342-57 and 2-58

2-65 and 2-662-105 and 2-1062-123 and 2-124



C2

By Order of the Secretaries of the Army, and the Air Force:

Official:

JOEL B. HUDSONActing Administrative Assistant to the

Secretary of the Army00112

GORDON R. SULLIVANGeneral, United States Army

Chief of Staff

MERRILL A. McPEAKGeneral, USAFChief of Staff

Official:

RONALD W. YATESGeneral, USAFCommander, Air force Materiel Command


TM 9-6115-641-24.

CHANGE

NO. 1


C1

HEADQUARTERSDEPARTMENTS OF THE ARMY, AND AIR FORCE

WASHINGTON, D.C., 15 DECEMBER 1993

TECHNICAL MANUAL

UNIT, DIRECT SUPPORT AND GENERAL SUPPORTMAINTENANCE MANUAL

GENERATOR SET, SKID MOUNTED, TACTICAL QUIET5 KW, 60 AND 400 HZ, MEP-802A (60 Hz) 6115-01-274-7387

MEP-812A (400 Hz) 6115-01-274-7391


TM 9-6115-641-24/TO 35C2-3-456-12, 1 SEPTEMBER 1993 is changed as follows:


Remove pages1-9 Through 1-121-25 and 1-262-9 and 2-102-13 Through 2-162-109 Through 2-1142-117 Through 2-1202-125 and 2-1262-131 and 2-132B-7 Through B-10C-1 and C-2

Insert pages1-9 Through 1-121-25 and 1-262-9 and 2-102-13 Through 2-162-109 Through 2-1142-117 Through 2-1202-125 and 2-1262-131 and 2-132B-7 Through B-10C-1 and C-2


ARMY TM 9-6115-641-24AIR FORCE TO35C2-3-456-12

Cl

By Order of the Secretaries of the Army, and Air Force:

Official:

MILTON H. HAMILTONAdministrative Assistant to the

Secretary of the Army

GORDON R. SULLIVANGeneral, United States Army

Chief of Staff

MERRILL A. McPEAKGeneral, USAFChief of Staff

Official:

RONALD W. YATESGeneral, USAFCommander, Air Force Materiel Command


TM 9-6115-641-24.

05824


High voltage is produced when this generator set is in operation. Improper opera-tion could result in personal injury or death.

Battery acid can cause burns to unprotected skin. Wear protective clothing in-cluding rubber gloves and eye protection when servicing the batteries. Failureto observe this warning could result in severe injury or death.

Batteries give off flammable gas. Do not smoke or use open frame when perform-ing maintenance. Flames and explosion could result in severe personal injury ordeath.

Exhaust discharge contains deadly gases. Do not operate generator sets in en-closed areas unless exhaust discharge is properly vented outside. Severe per-sonal injury or death due to carbon monoxide poisoning could result.

The fuels used in this generator set are highly explosive. Do not smoke or useopen frames when performing maintenance. Fire or explosion could cause seri-ous injury or death.

When filling the fuel tank, maintain metal-to-metal contact between filler nozzleand fuel tank opening. Failure to observe this warning could result in explosion,injury, or death.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin/eyeprotection required. Avoid repeated/prolonged contact. Good general ventilationis normally adequate.

Liquids under pressure are generated as a result of operation of the generatorset. High pressure leaks could cause severe personal injury or death.

.a


The coolant system operates at high temperatures. PersonaI injury or death fromburns or scalding could result from high pressure steam.

With any access door open, the noise level of this generator set when operatingcould cause hearing damage. Hearing protection must be worn when operatingor working near the generator set while running.

Never attempt to start the generator set if it is not properly grounded. Failure toobserve this warning could result in serious injury or death by electrocution.

Hot refueling of generator set, while operating, presents a safety hazard andshould not be attempted. Hot engine surfaces and sparks from the engine andgenerator circuitry are possible sources of ignition. Severe injury or death couldresult.

Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract.Skin/eye protection required. Avoid repeated/prolonged contact. Good generalventilation is normally adequate.

Remove metal jewelry when working on electrical system/components. Failureto observe this warning could cause severe personal injury or death by electrocu-tion.

Wear a protective mask and gloves when sanding CARC painted surfaces. CARCpaint dust is a health hazard and could cause personal injury if warning is notfollowed.

FOR FiRST AiD REFER TO FM 21-11

b

TECHNICAL MANUAL


HEADQUARTERSDEPARTMENTS OF THE ARMY AND AIR FORCE

WASHINGTON, D. C., 1 SEPTEMBER 1993

Unit, Direct Support and General Support Maintenance ManualGENERATOR SET, SKID MOUNTED, TACTICAL QUIET

5 KW, 60 and 400 HzMEP-802A (60 Hz) 6115-01-274-7387

MEP-812A (400 Hz) 6115-01-274-7391

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures,please let us know.

(A) Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form2028-2 located in back of this manual direct to:

COMMANDERU.S. ARMY AVIATION AND TROOP COMMANDATTN: AMSAT–I–MP4300 Goodfellow Blvd.St. Louis, MO 63120-1798

(F) Air Force - AFTO Form 22 directly to:

COMMANDERSACRAMENTO AIR LOGISTICS CENTERATTN: TILBAMcClellan AFB, CA 95652-5990 (AFMC)

A reply will be furnished to you.


i


TABLE OF CONTENTS

CHAPTER 1

Section I

Section Il.

Section Ill.

CHAPTER 2

Section I.

Section II

Section Ill.

Section IV.

Section V.

Section VI.

Section VIl.

Section Vlll.

Section IX.

Section X.

Section Xl.

Section XII.

Section XlIl.

Section XIV.

Section XV.

Section XVI.

Section XVlI.

Section XVlll.

CHAPTER 3

Section I.

Section Il.

Section Ill.

CHAPTER 4

Section I.

Section Il.

Section Ill.

Section IV.

Section V.

Section VI.

Section VIl.

PageHow To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Equipment Description And Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

UNIT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Upon Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Repair Parts; Special Tools; Test, Measurement, andDiagnostic Equipment (TMDE); and Special Support Equipment . . . . . . . . . . . . . . 2-7

Special Lubrication Instructions ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Preventive Maintenance Checks And Services (PMCS) . . . . . . . . . . . . . . . . . . . . . 2-8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Radio Interference Suppression ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Maintenance of DC Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Maintenance of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Maintenance of Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Maintenance of Output Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Maintenance of Air Intake And Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

Maintenance of Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

Maintenance of Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

Maintenance of Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

Maintenance of Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123

Maintenance of Load Output Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . 2-133

Preparation For Shipment And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

GENERAL MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Repair Parts; Tools; Test, Measurement, and DiagnosticEquipment (TMDE); and Special Support Equipment . . . . . . . . . . . . . . . . . . . . . 3-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Removal And Installation Of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

DIRECT SUPPORT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance of DC Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance of Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Maintenance of Output Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Maintenance of Coolant System ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Maintenance of Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Maintenance of Skid Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Maintenance of Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

ii

APPENDIX A

APPENDIX B

APPENDIX C

APPENDIX D.

Number

Table 1–1.

Table 1–2.

Table 2–1.

Table 2–2.

Table 2-3.

Table 2-4.

Table 2–5.

Table 2-6.

Table 2–7.

Table 2-8.

Table 2–9.

Table 2-10.

Table 3-1.

Table 4-1.

Table D–1.

Number

Figure 1–1.

Figure 1–2.

Figure 1–3,

Figure 1-4.

Figure 1–5.Figure 1-6.

Figure 1–7,Figure 1-8.

Figure 1–9.


TABLE OF CONTENTS - Continued

Page

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1

MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

EXPENDABLE/DURABLE SUPPLIES ANDMATERIALS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

FABRICATION/ASSEMBLY OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l–1

LIST OF TABLES

Title P a g e

Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Fabricated/Assembled Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Unit Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Unit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

State Of Charge With Specific GravityCorrected To 80°F (27°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Specific Gravity Temperature Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Voltage Adjustment Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Diagnostic Connector Connection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Direct Support Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Generator Resistance Values At 25°C(77°F) . . . . . . . . . . . . . . . . . . . . . . . . .4-21Inches To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13

LIST OF ILLUSTRATIONS

Title Page

Generator Set, 5kW, Tactical Quiet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Fault System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Generator Set Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Generator Set Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Engine Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Output Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Engine Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

iii


Number

Figure 1–10.

Figure 1–11.

Figure 1-12.

Figure 2–1.

Figure 2–2.

Figure 2-3.

Figure 2-4.

Figure 2–5.

Figure 2-6.

Figure 2–7.

Figure 2-6.

Figure 2–9.

Figure 2–10.Figure 2–11.

Figure 2-12.

Figure 2–1 3.

Figure 2–14.

Figure 2-15.

Figure 2–1 6.

Figure 2-17.

Figure 2-18.

Figure 2–19.

Figure 2–20.

Figure 2–21.

Figure 2–22.

Figure 2-23.

Figure 2–24.

Figure 2–25.

Figure 2-26.

Figure 3-1.

Figure 4-1.

Figure 4-2.

Figure 4-3.

Figure 4-4.

Figure 4-5.

Figure 4-6.

Figure 4-7.

Figure 4-8.

Figure 4–9.

i v

LIST OF ILLUSTRATIONS - Continued

Title Page

Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Voltage Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Generator Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Minimum Enclosure Clearance Measurements . . . . . . . . . . . . . . . . . . . . . . . 2-5

Base Mounting Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Batteries and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

NATO Slave receptacle and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Battery Charging Alternation , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Generator Set Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Control Box Top Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Generator Set front Housing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Generator set rear Housing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Diode Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Diagnostic Connector Pin Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Control Panel indicators and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

Control Box Housing and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

Output Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

Pre-Heat RelayTerminats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98

Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-101

Radiator Assembly and cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

Fuel Tank, Switches, and Auxiliay Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . 2-114

Fuel Filter/Water Separator and Transfer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119

Engine Oil Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122

Frequency Adjust Control Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123

Engine Related Switches and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125

Load Output Terminal Board Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134

Engine and Generator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Housing Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Brush Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Diode-Trio Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Rectifier Bridge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Stator Winding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Rotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Alternator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Assembling Front Housing to Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Performance Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Number

Figure 4-10.

Figure 4-11.

Figure 4-12.

Figure 4-13.

Figure 4-14.

Figure 4-15.

Figure 4-16.

Figure 4-17.

Figure 4-18.

Figure 4-19.

Figure 4-20.

Figure 4-21.

Figure 4-22.

Figure 4-23.

Figure 4-24.

Figure 4-25.

Figure D-1.

Figure D-2.

Figure D-3.

Figure D-4.

Figure D-5.

Figure D-6.

Figure D-7.

Figure D-8.

Figure D-9

Figure D-1 0.

Figure D-11.

Figure D-12.

Figure D-13.

Figure D-14.


LIST OF ILLUSTRATIONS - Continued

Title Page

Control Box Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Output Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Testing Current Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Frequency Droop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Skid Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Generator Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Excitation Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Testing Rotating Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Testing Exciter Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Testing Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Testing Rotor for an Open or Shorted Windings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Testing Rotor for Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Testing Stator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Support of Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Generator Assembly (MEP-802A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Generator Assembly (MEP-812A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Cable Assembly, Battery (P/N: 88-20312) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Cable Assembly, Battery (P/N: 88-20313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Cable Assembly (P/N: 88-20314) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Cable Assembly, Battery (P/N: 88-20315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Cable Assembly Battery (P/N: 88-20316) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--6

Cord, Load Wrench (P/N: 88-22460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–7

Diode Assembly (P/N: 88-22418-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7

Holder, Control Panel (P/N: 88-20134) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

insulation, Skid (P/N: 88-20296) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–9

Pump Assembly Fuel (P/N: 88-20479) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

Pump Assembly Fuel (P/N: 88-22546) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

Solenoid Assembly, Fuel (P/N: 88-20482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11

Transducer Assembly (P/N: 88-20480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–11

Wire, Varistor (P/Ns: 88-20305-1 through 88-20305-4) . . . . . . . . . . . . . . . . . . . . D–12

v


HOW TO USE THIS MANUAL

In this manual (TM 9-6115-641-24), paragraphs are underlined and the sections and chapters appear in capital letters. Thelocation of additional material that must be referenced is clearly marked. Illustrations in this text are located as close aspossible to their references.

Chapter 1- INTRODUCTION. Contains general information, equipment description and data, and principles of operationfor the generator set.

Chapter 2- UNIT MAINTENANCE INSTRUCTIONS. Contains information on servicing the generator set and compo-nents upon receipt, Unit level Preventive Maintenance Checks and Services (PMCS), troubleshooting procedures usedto recognize and correct generator set malfunctions, and all maintenance procedures authorized at Unit level.

Chapter 3- GENERAL MAINTENANCE INSTRUCTIONS. Contains Direct Support level troubleshooting proceduresused to recognize and correct generator set malfunctions, and procedures for the removal and installation of major compo-nents.

Chapter 4- DIRECT SUPPORT MAINTENANCE INSTRUCTIONS. Contains all maintenance procedures authorized tobe performed on the generator set at the Direct Support level.

APPENDICES.

Appendix A is a list of publications referenced in this manual and should be used in conjunction with this manual.

Appendix B is the Maintenance Allocation Chart (MAC) which designates all maintenance and repair functions authorizedto be performed at the different maintenance levels.

Appendix C is the Expendable/Durable Supplies and Materials List (EDSML) which lists all expendable/durable suppliesand materials required in performing the maintenance procedures presented in this manual.

Appendix D lists all parts that require fabrication or assembly for the maintenance of the generator set. Materials and pro-cedures required are included.

Index. The index contains key technical manual subjects arranged in alphabetical order. If you require information on aspecific subject (i.e., Time Meter), but you are not sure where to look, use the index to locate specific paragraph.

vi


CHAPTER 1

INTRODUCTION

Section I. GENERAL INFORMATION

1-1. SCOPE.This manual contains Unit, Direct Support and General Support maintenance instructions for the Tactical Quiet (TQ), 5kW 60 and 400 Hz Generator Sets (FIGURE 1–1 ), herein referred to as generator sets. Included are descriptions of majorcomponents and their functions in relation to other components.

Mode Number Equipment NameMEP-802A Generator Set,

Skid Mounted,Tactical Quiet5 kW 60 Hz

MEP-812A Generator Set,Skid Mounted,Tactical Quiet5 Kw 400 HZ

The generator set provides tactical quiet AC power. The generator set is easily transported, operated, and maintained.

1-2. LIMITED APPLICABILITY.Some portions of this publication are not applicable to all services. These portions are prefixed to indicate the service(s)to which they pertain: (A) for Army, (F) for Air Force, and (N) for Navy.

1-3. MAINTENANCE FORMS AND RECORDS.1-3-1. (A) Department of the Army forms and procedures used for equipment maintenance will be those prescribed byDA PAM 738-750, The Army Maintenance Management System (TAMMS).

1-3-2. (F) Maintenance forms and records maintained by the Air Force are prescribed in AFR 66-1 and the applicableTO 00-20 Series Technical Orders.

1-3-3. (N) Navy users should refer to their service peculiar directives to determine the applicable maintenance formsand records to be used.

1-4. REPORTING OF ERRORS.Reporting of errors, omissions, and recommendations for improvement of this publication by the individual user is encour-aged. Reports should be submitted as follows:

1-4-1. (A) Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form2028-2 located in back of this manual direct to:

Commander U.S. Army Aviation and Troop CommandAttn: AMSAT–I–MP4300 Goodfellow Blvd.St. Louis, MO 63120-1798

1-4-2. (F) Air Force – AFTO Form 22 directly to:

1-4-3.

CommanderSacramento Air Logistics Center (AFMC)Attn: TILBAMcClellan AFB, CA 95652-5990

(N) Navy - by letter directly to:CommanderU.S. Navy Ships Parts Control CenterAttn: Code 783Mechanicsburg, PA 17055

1-1


Figure 1-1. Generator Set, 5 kW, Tactical Quiet

1-2


1-5. EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs).

1-5-1. If your generator set needs improvement, let us know. Send us an EIR. You, the user, are the only one who cantell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. We will sendyou a reply.

1-5-2. (A) Put it on an SF 368 (Product Quality Deficiency Report). EIRs should be mailed directly to:

CommanderU.S. Army Aviation and Troop CommandAttn: AMSTR–MOF4300 Goodfellow Blvd.St. Louis, MO 63120-1798

1-5-3. (N) Put it on applicable Navy form and mail it directly to:

Naval Construction Battalion CenterAttn: Code 157Civil Engineer Support Office (CESO)Port Hueneme, CA 93043-5000

1-5-4. (F) Send QDR/MDR by electric message to:

SMALCMcClellan AFB CA//TlLBE//

For technical assistance notify:

SM-ALC/LIEAEAttn: Equipment Specialist, TQGMcClellan AFB, CA 95652–5990

1-6. LEVELS OF MAINTENANCE

1-6-1. (A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to beperformed.

1-6-2. (F) Refer to the Source Maintenance Recoverability (SMR) Codes for maintenance to be performed.

1-6-3. (N) Navy users shall determine their maintenance levels in accordance with their service directives.

1-7. DESTRUCTION OF MATERIEL TO PREVENT ENEMY USE.

1-7-1. (A) Destruction of the generator set to prevent enemy use shall be in accordance with TM 750-244-3.

1-7-2. (F) (N) Air Force and Navy users shall refer to their service directives to obtain procedures for destruction of mate-riel to prevent enemy use.

Section Il. EQUIPMENT DESCRIPTION AND DATA

1-8. GENERAL.

The generator sets, models MEP-802A and MEP-81 2A, (Figure 1–1 ) are fully enclosed, self-contained, skid–mounted,portable units. They are equipped with controls, instruments, and accessories necessary for operation as single units.The generator sets consist of a diesel engine, brushless generator, excitation system, speed governing system, fuel sys-tem, 24 VDC starting system, control system and fault system.

1-9. TABULATED/ILLUSTRTED DATA.

For a list of Tabulated Data refer to Table 1–1.

1-3


Table 1-1. Tabulated Data

1 Generator Set:

a. National Stock Number

b. Overall Length

c. Overall Width

d. Overall Height

e. Dry Weight (less BasicIssue Items List)

f. Wet Weight

2 Engine:

a.

b.

c.

d.

e.

f.

g.

h.

Manufacturer

Model

Type

Displacement

Altitude Degradation,4000 ft. (1220 m) to8000 ft. (2440 m)

Firing Order

Cold Weather StartingAid System Use

Valve Tappet ClearanceAdjustment:

3 Cooling System:

a. Type

b. Capacity

c. Normal OperatingTemperature

d. Temperature IndicatingSystem Voltage Rating

4 Lubricating System:

a. Type

b. Oil Pump Type

c. Normal OperatingPressure

d. Oil Filter Type

e. Capacity

f. Pressure IndicatingSystem Voltage Rating

MEP-802A

6115-01-274-7387

50.6 in. (128.6 cm)

32 in. (81 .28 cm)

37 in. (93.98 cm)

800 lb (362.8 kg)

868 lb (393.7 kg)

Onan

DN2M

Two cylinder, four cycle, naturallyaspirated diesel

57 cu in. (0.9 liters)

3.5% per 1000 ft (305 m)

1,2

40°F (4°C) to –25°F (–32°C)

None Required

Pressurized radiator and pump

6.2 qts (5.9 liters)

170-200°F (77–93°C)

24 VDC

Full flow, circulating pressure

Positive displacement gear

25-60 psi (172-414 kPa)

Full flow, spin-on replacementelement


24 VDC

MEP-812A

6115-01-274-7391

50.6 in. (128.6 cm)

32 in. (81 .28 cm)

37 in. (93.98 cm)

825 lb (374.2 kg)

678 lb (398.2 kg)

Onan

DN2M

Two cylinder, four cycle, naturallyaspirated diesel

57 cu in. (0.9 liters)

3.5% per 1000 ft (305 m)

1, 2

40°F (4°C) to –25°F (–32°C)

None Required

Pressurized radiator and pump


170-200°F (77–93°C)

24 VDC

Full flow, circulating pressure

Positive displacement gear

25-60 psi (172-414 kPa)

Full flow, spin-on replacementelement


24 VDC

1-4


Table 1-1. Tabulated Data - Continued

5 Fuel System:

a. Type of Fuel

b. Fuel Tank Capacity

C. Fuel Consumption Rate

d. Auxiliary Fuel Pump:

(1) Voltage Rating

(2) Delivery Pressure

e. Fuel Level Switch:

(1) Type

(2) Current

6 Engine Starting System:

a. Batteries

b. Starter:

(1) Manufacturer

(2) Model

(3) Voltage Rating

(4) Drive Type

C. Battery ChargingAlternator:

(1) Manufacturer

(2) Model

(3) Rating

(4) Protective Fuse

7 AC Generator:

a. Manufacturer

b . Type

C. Load Capacity

d. Current Ratings:

(1) 120/240 voltconnection

(2) 120/208 voltconnection

(3) 120 volt connection

e. Power Factor

f. Cooling

g. Drive Type

h. Duty Classification

MEP-802A

DF-1, DF-2, DF-A, JP4, JP5, JP8

5 gal. (18.9 liters)

.55 gal. (2.1 liters) per hour

24 VDC

5-6.5 psi (34.5-65.5 kPa) (max)

Float

0.6 amps (min) at 24 VDC

Two 12 volt, connected in series

Onan

191-1550

24 VDC

Gear reduction

Prestolite

8EM3005CA

18 amps at 24 VDC

30 amps

Onan

Rotating field, synchronous

5 KW

26 amps

17 amps

52 amps

0.8

Fan Cooled

Direct Coupling

Continuous

MEP-812A

DF-1, DF-2, DF-A, JP4, JP5, JP8

5 gal. (18.9 liters)

.61 gal. (2.3 liters) per hour

24 VDC

5-6.5 psi (34.5-65.5 kPa) (max)

Float

0.6 amps (min) at 24 VDC

Two 12 volt, connected in series

Onan

191-1550

24 VDC

Gear reduction

Prestolite

8EM3005CA

18 amps at 24 VDC

30 amps

Onan

Rotating field, synchronous

5KW

26 amps

17 amps

52 amps

0.8

Fan Cooled

Direct Coupling

Continuous

Change 2 1-5


Table 1-1. Tabulated Data - Continued

8 Protection Devices:

a. Low Oil Pressure Switch:

(1) Trip Pressure

(2) Voltage Rating

(3) Current Rating

b. Coolant HighTemperature Switch:

(1) Trip Temperature

(2) Voltage Rating

(3) Current Rating

c. Overvoltage Relay:

(1) Trip PointCondition

(2) Trip Point

MEP-802A

15 ± 3 psi (103.4 ± 20.7 kPa)

24 VDC

7 amps

225 ± 5°F (107 ± 3°C)

24 VDC

7 amps

153 ± 3 VAC for no less than 200milliseconds (120 VAC coil winding)

No more than 1.25 seconds aftertrip conditions exist

MEP-812A

15 ± 3 psi (103.4 ± 20.7 kPa)

24 VDC

7 amps

225 ± 5°F (107 ± 3°C)

24 VDC

7 amps

153 ± 3 VAC for no less than 200milliseconds (120 VAC coil winding)

No more than 1.25 seconds aftertrip conditions exist

1-10. DIFFERENCES BETWEEN MODELS.

1-10-1. The differences between models of the generator sets covered in this manual are as follows:

a. Model MEP-802A is equipped with a 60 Hz generator and 60 Hz frequency meter.

b. Model MEP-812A is equipped with 400 Hz generator and 400 Hz frequency meter.

1-10-2. Performance characteristics for the two models are shown in Table 1-2.

Table 1-2. Performance Characteristics

1 Voltage:

(a) Voltage waveformDeviation factor:

Single phaseThree phase

Single voltageharmonics:

Single phaseThree phase

(b) Voltage unbalance

(c) Phase balance voltage

(d) Voltage modulation

(e) Voltage regulation

(f) Short-term stability(30 seconds)

(g) Long-term stability(4 hours)

MEP-802A

6% (max)5% (max)

3% (max)2% (max)

5% of rated voltage (max)


2.5% (max)

3% (max)

± 2% of rated voltage


MEP-812A

6% (max)5% (max)

3% (max)2% (max)


1% of fated voltage (max)

2.5% (max)

3% (max)



MEP-802A MEP-812A

(h) Voltage drift (60°F 2% (max) 2% (max)(16°C) in 8-hour period)

(i) Dip and rise for rated load 20% of rated voltage (max) 20% of rated voltage (max)

Recovery time 3 seconds 3 seconds

(j) Dip for low power factor load 35% of no-load voltage (max) 35% of no-load voltage (max)

Recovery time 5 seconds 95% of no–load voltage 5 seconds 95% of no-load voltage

(k) Adjustment range VAC 60 HZ 400 Hz120V connection 114-126V 114-126V120/240V connection 228-252V 228-252V120/208V connection 205–220V 205–220V

2 Frequency:

(a) Regulation 3% of rated frequency 3% of rated frequency

(b) Short-term steady-state 2% of rated frequency 2% of rated frequencystability (30 seconds)

(c) Long-term steady-state 3% of rated frequency 3% of rated frequencystability (4 hours)

(d) Frequency drift (60°F 2% (max) 2% (max)(16°C) in 8 hour period)

(e) Undershoot with 3% of rated frequency (max) 3% of rated frequency (max)application of load

Recovery time 3 seconds 3 seconds

(f) Overshoot with 4% of rated frequency (max) 4% of rated frequency (max)application of load

Recovery 3 seconds 3 seconds

(9) Adjustment range ± 3% for 60 Hz ± 3% for 400 Hz


Table 1-2. Performance Characteristics - Continued

Section Ill. PRINCIPLES OF OPERATION

1-11. INTRODUCTION.

This section contains functional descriptions of the generator set and explains how the controls and indicators interactwith the systems, and the location and description of major components.

1-12. PRINCIPLES OF OPERATION.

1-12-1. Fault System

1-12-1-1. The Fault System (Figure 1–2) protects the generator set and any connected load against the potential faultsdescribed below and provides an indication of any incurred fault. The following summary of the Fault System will assistin understanding the operation of other generator set systems. Additional details relating to specific protection devicesare provided in the descriptions of the respective systems.

1-12-1-2. The Fault System consists of the malfunction indicator, low fuel level float switch, fuel float switch module,fuel level relay, low oil pressure switch, oil pressure relay, coolant high temperature switch, overvoltage relay, overload/short circuit relay, engine fault relay, and BATTLE SHORT switch. In addition to the fault indicator lamps, the malfunctionindicator includes the PUSH TEST & RESET LAMPS switch which when depressed, illuminates all the lamps and resetsany fault indication.

1-7


1-12-1-3. Activation of anyone of the following protection devices will cause three evants to occur. The AC circuit inter-rupter relay holding circuit will be deenergized causing the AC circuit interrupter relay to open; the generator set enginewill be shutdown; and a fault indicator lamp will be illuminated to show which malfunction occurred.

1-12-1-3-1. Coolant High Temperature Switch. This device will activate when the engine coolant leaving the engineexceeds 225 ± 5°F (107 ± 3°C).

1-12-1-3-2. Low Oil Pressure Switch. This device activates when the engine lubrication oil pressure falls below 15±3 psi (103.4 ± 20.7 kpa).

1-12-1-3-3. Low Fuel Level Float Switch. This device will activate when the fuel Ievel falls to a point at which the operat-ing time of the set at rated Ioad is four minutes.

1-12-1-3-4. Overvoltage Relay. This device will activate when the 120-volt generator coil winding has risen to and re-mained at any value greater than 153 ± 3 volts.

1-12-1-4. Fuel Float Switch Module. This device prevents inadvertent engine shutdown by providing a one second delayafter actuation of the low fuel level float switch.

1-12-1-5. Activation of any of the following electrical protection devices will cause two events to occur. The AC circuitinterrupter relay will open and a fault indicator lamp will illuminate to indicate which fault occurred.

1-12-1-5-1. Short Circuit Relay. This device will activate when the set output current in any phase exceeds 425X 25percent of the rated value.

1-12-1-5-2. Overload Relay. This device will operate when the load current in any phase exceeds 110 percent of ratedvalue.

1-12-1-6. Although it is possible for more than one fault to occur at one time during operation, only the first fault to occurwill be displayed by the malfunction indicator. The activated indicator lamp circuit remains illuminated until the malfunctionindicator is reset. The lamp will be off with the MASTER SWITCH in the OFF position and will be re-illuminated when theMASTER SWITCH is turned to one of the RUN positions. Resetting a fault indication is done in two steps. First push thePUSH TEST & RESET LAMPS switch located on the malfunction indicator. Then move the MASTER SWITCH to the OFFposition. The generator set cannot be cranked unless both actions are completed. The indicated fault must be correctedbefore any attempt is made to restart the generator set or dose the AC circuit interrupter relay.

1-8


Figure 1-2. Fault System

1-9


1-12-1-7. After the generator set engine has been started, the BATTLE SHORT switch can be used to override all ofthe potential faults except short circuit.

1-12-2. Fuel System.

1-12-2-1. The Fuel System (Figure 1–3) includes a primary subsystem and an auxiliary subsystem.

1-12-2-2. The primary subsystem consists of fuel lines, fittings, fuel tank, low fuel level float switch, fuel float switchmodule, fuel level sender, FUEL LEVEL indicator, fuel transfer pump, fuel filter/water separator, two injection pumps, andtwo injectors.

1-12-2-3. Injection pump output is controlled by a mechanical engine governor. The governor also includes a fuel sole-noid operated shutoff lever which stops operation of the injection pumps when the solenoid is deenergized. With the MAS-TER SWITCH in the START or either of the two RUN positions, both the fuel solenoid and the fuel transfer pump are ener-gized. The fuel solenoid positions the shutoff lever to the open position, and the transfer pump starts drawing fuel fromthe fuel tank. After reaching the fuel transfer pump, fuel passes through a fuel filte/water separator where water and smallimpurities are removed. The fuel then goes to the injection pumps. With the engine cranking or running the fuel is metered,pressurized and pushed through the injectors by the injection pumps. Fuel is sprayed by the injectors into the engine com-bustion chamber where it is mixed with air and ignited. The fuel that is not burned by the engine is returned to the fueltank by an excess fuel return line. Power is removed from the fuel solenoid and the transfer pump, stopping the enginewhenever the MASTER SWITCH is turned to OFF position. The fuel solenoid and transfer pump are also de-energizedby the fault system (refer to paragraph 1-12-1). The fuel level sender measures tank fuel level which is indicated by theFUEL LEVEL indicator from E (empty) to F (full).

1-12-2-4. The auxiliary subsystem consists of anauxiliary fuel supply, fuel lines, fittings, auxiliary fuel filter, auxiliary fuelpump, auxiliary fuel pump float switch located in the fuel tank, and a fuel float switch module.

1-12-2-5. When the MASTER SWITCH is set on PRIME & RUN AUX FUEL, it actuates the auxiliary fuel pump andtransfers fuel from the auxiliary fuel supply to the fuel tank. The auxiliary fuel pump float switch shuts off the auxiliary fuelpump when the fuel tank is full and reactivates the pump as the level drops. The fuel float switch module allows the currentused by the auxiliary fuel pump to bypass the float switch.

1-12-2-6. The 24 VDC control circuits provide control and power for operation of the fuel solenoid, indicators, fuel trans-fer pump, and auxiliary fuel pump.

1-10 Change 1


Figure 1-3. Generator Set Fuel System

Change 1 1-11


1-12-3. Generator Set Cooling System.

1-12-3-1. The Generator Set Cooling System (Figure 1-4) includes air intake and exhaust grilles, baffles, and ductingwithin the generator set housing and the engine driven radiator cooling fan. The air intake grilles are Iocated in panels onboth sides of the generator set housing. The air exhaust grille is located in the housing top panel.

1-12-3-2. Air is drawn in through the air intake grilles and forced through the engine coolant radiator and outof the gener-ator set through the exhaust grille by the radiator cooling fan. Some of the air drawn into the housing is used by the EngineIntake and Exhaust System (refer to paragraph 1-12-6). Most of the cooling airflows externally past the generator assem-bly and engine, Some cooling air is circulated internally through the AC generator assembly by a generator fan which isan integral part of the AC generator assembly. Baffles, ducting, and sound absorbing material are used to control the airflow through the generator set and to reduce sound transmission through the grilles

1-1241. The Engine Coding System (Figure 1-5) consists of a radiator, hoses, thermostat, temperature sender, cool-ant high temperature switch, COOLANT TEMP. indicator, water pump, a belt driven fan, and cooling jackets (part of en-gine).

1-1242. The water pump forces coolant through passages (cooling jackets) in the engine block and cylinder headwhere the coolant absorbs heat from the engine. When the engine reaches normal operating temperature, the thermostatopens and the heated coolant flows through the upper radiator hose assembly into the radiator. The cooling fan circulatesair through the radiator where the coolant temperature is reduced.

1-12-4-3. A coolant high temperature switch in conjunction with the fault system provides automatic shutdown in theevent that coolant temperature exceeds 225 ± 5°F (107 ± 3°F). The COOLANT TEMP. indicator indicates the engine cool-ant temperature, from 120°F to 240°F (48°C to 115°C).

1-12-5. Engine Lubrcation Svsterm.

1-12-5-1. The Engine Lubrication System (Figure l-6) consists of an oil sump, dipstick, pump, oil pressure sender, OILPRESSURE indicator, low oil pressure switch, and filter.

1-12-5-2. The oil sump is a reservoir for engine lubricating oil. The dipstick indicates oil level in the sump. The oil levelcan only be checked when the engine is not running. The pump draws oil from the sump through a screen removing largeimpurities. The oil then passes through a spin-on type filter where small impurities are removed. From the filter, oil is dis-tributed to the engine’s internal moving parts and then retums to the oil sump. The oil pressure sender located in the enginecrankcase senses oil pressure. The oil pressure is displayed on the OIL PRESSURE indicator. The Iow oil pressure switch,also located in the engine crankcase, functions with the generator set fault system. The engine is automatcally shut offif the oil pressure drops below 15 ± 3 psi (103.4 ± 20.7 kPa).

1-12

1-12-4. Engine Cooling System.


Figure 1-4. Generator Set Cooling System

1-13


Figure 1-5. Engine Cooling System

1-14 Change 2


Figure 1-6. Engine Lubrication System

1-15


1-12-6-1. The Engine Air Intake and Exhaust System (Figure 1-7) consists of an air cleaner assembly, intake manifold,two heater plugs, exhaust manifold, and muffler. The air cleaner assembly includes a dust collector, filter element, andrestriction indicator.

1-12-6-2. Air is drawn into the dust collector and Passes through the filter element. Airborne dirt is removed and trappedin the dust collector and filter element. The restriction indicator indicates when the filter should be serviced. Filtered airis drawn out of the filter through air intake tubes to the intake manifold where it passes into the engine.

1-12-6-3. The engine exhaust gases are expelled into the exhaust manifold. The exhaust manifold channels the gasesinto the muffler that deadens the sound of the exhaust gases. The gases pass from the muffler through the muffler outletand are vented upward from the generator set housing. A cover, which is held open by the pressure of the exhaust gasesduring operation, doses over the exhaust port to prevent rain, water, or other foreign matter from entering the exhaustport when the set is not in use. The cover is easily removed for connection of an exhaust pipe for indoor operation.

1-12-64. To improve engine starting when ambient temperature is below 40°F (4°C), two heater plugs are located inthe intake manifold. The heater plugs are energized through the preheat relay when the MASTER SWITCH is held in thePREHEAT position.

1-12-6-5. The DC control circuit provides power to the preheat relay and heater plugs.

1-12-7. Output Supply System.

1-12-7-1. The Output Supply System (Figure 1-8) consists of the AC generator, AC voltage reconnection switch,GROUND FAULT CIRCUIT INTERRUPTER (GFCI), CONVENIENCE RECEPTACLE, current transformer, AC circuit in-terrupter relay, load terminals, AC CIRCUIT INTERRUPTER switch, AM-VM transfer switch, AC voltmeter (VOLTS AC),ammeter (PERCENT RATED POWER), frequency transducer, and FREQUENCY meter (HERTZ).

1-12-7-2. Power created by the AC generator is supplied through the current transformer, AC voltage reconnectionswitch, and AC circuit interrupter relay to the load terminals. The AC voltage reconnection switch allows configuration ofthe generator set for the following voltage connections: 120 volt, single phase, 2 wire; 120/240 volt, single phase, 3 wire;and 120/208 volt, 3-phase, 4 wire. The AC generator also provides 120 VAC to the CONVENIENCE RECEPTACLEthrough the GROUND FAULT CiRCUiT INTERRUPTER.

1-12-7-3. The AC CIRCUIT INTERRUPTER switch doses and opens the AC circuit interrupter relay. This enables orinterrupts the power flow between the AC voltage reconnection switch and the load terminals. The voltage regulation sys-tem (refer to paragraph 1-12-10) senses generator output voltage and provides a control signal to the generator exciterto maintain the desired generator output voltage. Generator output frequency is controlled by the governor control system(refer to paragraph 1-12-9), sensed by the frequency transducer and is read on the FREQUENCY meter (HERTZ). Thecurrent transformer provides a reduced current signal to the ammeter (PERCENT RATED CURRENT) which indicatesthe percent of rated current being supplied to the load. The position of the AM-VM transfer switch selects the Ioad terminalfrom which current and voltage are measured. The AC circuit interrupter relay will open and disconnect the load wheneveran overload or short circuit occurs.

1-16

1-12-6. Engine Air Intake and Exhaust System.


Figure 1-7. Engine Air Intake and Exhaust System

1-17


Figure 1-8. Output Supply System

1-18


1-12-7-4. The GND (ground terminal) is connected to the generator set skid base. This terminal is also connected tothe ground rod for all generator set operation. The removable link provides a removable, low inductance connection be-tween LO and GND terminals. This removable link must be in place for all generator set operation except when the loadinstructions specifically require its removal.

1-12-8. Generator Set Control%

1-12-8-1. Engine Starting System.

1-12-8-1-1. Engine starting (Figure 1-9) is accomplished primarily with two 12-volt batteries, connected in series toprovide 24 VDC power, and a starter. The starter includes a cranking motor and solenoid. To permit engine starting, theDC CONTROL POWER circuit breaker must be pushed in, the DEAD CRANK switch must be in the NORMAL positionand the BATTLE SHORT switch must be in the OFF position. In addition, any ENGINE SHUTDOWN fault previously regis-tered on the malfunction indicator panel must have been corrected, and the malfunction indicator panel must have beenreset. When the MASTER SWlTCH is then placed in the START position, the starting circuits supply 24 VDC power tothe starter. As the engine accelerates to approximately 900 rpm, the starting circuits disconnect power from the starterand energize the field flash relay. After the needle of the AC voltmeter (VOLTS AC) reaches rated voltage, indicating thatthe generator is producing power, the MASTER SWITCH can be moved to one of the two RUN positions for generatoroperation.

1-12-8-1-2. When the MASTER SWITCH is first moved to the START position, the various instrument and control cir-cuits including two starting control circuits are energized. One starting control circuit supplies 24 VDC power directly tothe control function of the crankdisconnect switch and also energizes the coil of the crank disconnect relay through closedcontacts of BATTLE SHORT switch and crank disconnect switch. The other starting control circuit directly energizes thecoil of the field flash relay and also energizes the cranking relay coil through closed contacts of the engine fault relay andcrank disconnect relay. With the cranking relay energized, power passes from the batteries through closed contacts ofthe cranking relay to energize the solenoid and the pulling coil of the fuel solenoid. With the solenoid energized, powerpasses from the batteries through closed contacts of the solenoid to the cranking motor. The cranking motor then cranksthe engine. As the engine accelerates to approximately 900 rpm, the magnetic pickup, which senses engine speed,causes the crank disconnect switch to break the circuit to the coil of the crank disconnect relay and dose the contactsof the field flash relay. When the MASTER SWITCH is moved to one of the RUN positions, both starting control circuitsare deenergized while the instrument and other control circuits remain energized. The fuel solenoid holding coil remainsenergized.

1-12-6-1-3. The engine may be cranked without starting by use of the DEAD CRANK switch. With the DEAD CRANKswitch in the CRANK position, the cranking relay coil is energized to initiate engine cranking without energizing any otherstarting or control function.

1-19


Figure 1-9. Engine Starting System

1-20


1-12-8-1-4. The generator set can be started without batteries by connecting an external 24 VDC power source to theNATO SLAVE RECEPTACLE. The generator set can also supply starting power to another set through the NATO SLAVERECEPTACLE.

1-12-8-1-5. The batteries are charged by the battery charging alternator that is belt driven by the engine. Generatorset control system power is also supplied by the battery charging alternator. The BATTERY CHARGE ammeter indicatesthe charge rate of the batteries, from -10 to +20 amps. The ammeter is connected to a shunt which provides a DC voltagesignal, which is directly proportional to the battery current flow, to the BATTERY CHARGE ammeter. Normal operatingindication depends on the state of charge in the batteries. A low charge which can exist immediately after engine starting,will cause a high reading (needle moves toward CHARGE area). When the charge in the batteries has been restored,the indicator moves near zero (0). The battery charging system is protected from a reverse polarity when connecting thebatteries by a fuse and diode.

1-12-8-2. Field Flash. When the engine reaches sufficient speed (900 rpm), the magnetic pickup causes a setofmntactsin the crank disconnect switch to open and de-energize the crank disconnect relay. A set of contacts in the crank discon-nect relay then doses and energizes the Field Flash circuit through dosed contacts of the field flash relay (refer toFigure 1-9). This provides current to the AC generator exciter field windings which sets up an electromagnetic field. Thefield current is necessary for the set to generate sufficient voltage for the voltage regulator (refer to Figure 1-11) to begincontrolling the output voltage of the generator set. The Field Flash circuit is maintained until the MASTER SWITCH isreleased from the START position.

1-12-8-3. Operation. Placing the MASTER SWITCH in the PRIME & RUN or PRIME RUN AUX positions keeps the fuelsolenoid energized, and fuel will be supplied to the engine as long as no fault condition exists. During operation, the opera-tor should periodically check the set’s instruments to ensure they are reading in the normal operating ranges. The VOLT-AGE and FREQUENCY adjust controls are adjusted as required to maintain the desired frequency and voltage output.

1-12-8-4. Applying the Load. The load is applied by dosing the AC CIRCUIT INTERRUPTER switch (refer toFigure 1-8). This is a momentary contact switch that returns to the neutral, or center position. The AC circuit interrupterrelay is energized by this momentary contact, and a holding circuit keeps it dosed, bringing the load on line.

1-12-8-5. Shutdown.

1-12-8-5-1. The AC circuit interrupter relay is disengaged by placing the AC CIRCUIT INTERRUPTER switch in theOPEN position. This is a momentary contact switch which will break the AC circuit interrupter relay holding circuit andthen return to the neutral, or center position, disconnecting the load from the line.

1-12-8-5-2. When the MASTER SWITCH is placed in the OFF position, all power is removed from the control circuitand the engine will stop.

1-12-6-5-3. The EMERGENCY STOP switch will remove power from the control circuit by energizing the engine faultrelay. This will cause the engine to shut down. The EMERGENCY STOP switch is not to be used as an alternative forroutine shutdown procedures. When the generator set is stopped using the EMERGENCY STOP switch, some circuitsremain energized causing a drain on the batteries until the MASTER SWITCH is placed in the OFF position.

1-12-9. Governor Control System.

1-12-9-1. The Governor Control System (FIGURE 1-10) includes the FREQUENCY ADJUST control, mechanical en-gine governor, engine fuel pump rack and fuel solenoid.

1-12-9-2. The mechanical engine governor is housed under the engine gear cover and moves the fuel pump rack, chang-ing fuel delivery of the injection pumps in proportion to engine load. The governor is a flyweight type, with the weightsmounted on the engine camshaft gear. The force of the flyweights is transferred through a thrust sleeve and collar to thegovernor lever, and balanced against the tension of the governor spring, which is stretched between the governor leverand the speed adjustment lever. Engine speed and generator output frequency are increased by increasing the tensionon the main governor spring. Droop is adjusted by varying the location of the governor spring’s mounting to the governorlever, effectively varying the strength of the spring.

1-12-9-3. The governor uses one Iever for fuel shutoff and the other for speed adjustment. The shutoff lever is operatedby the fuel solenoid in an energize-to-run configuration (fail safe). The speed adjustment lever is moved by a verniercontrol cable from the FREQUENCY ADJUST control of the set and provides an adjustment range of ± 3 percent of ratedfrequency.

1-21


The Voltage Regulation System (Figure 1–11) consists of the voltage regulator and VOLTAGE adjust potentiometer. Thevoltage regulator senses and controls the generator output voltage which is operator adjustable within the design limitsby use of the VOLTAGE adjust potentiometer. The output voltage to the load is indicated by the AC voltmeter (VOLTSAC) on the control panel assembly.

1-13. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

NOTEAll locations (Figure 1–12) referenced herein are given facing the control box side (rear)of the generator set.

1-13-1. Oil Filter (1). The oil filter is located in the engine compartment on the left side. The filter removes impurities fromthe engine lubricating oil.

1-13-2. Dipstick (2). The dipstick is located in the engine compartment on the left side. The dipstick shows the lubricatingoil level in the engine crankcase.

1-13-3. Fuel Filter/Water Separator (3). The fuel filter/water separator is located to the rear of the engine compartmenton the left side. The element removes impurities and water from the diesel fuel.

1-13-4. AC Generator (4). The AC generator is a single bearing, dripproof, synchronous, brushless, three phase, fan-cooled generator. The generator is coupled directly to the rear of the diesel engine.

1-22

1-12-10. Voltage Regulation System.


Figure 1-10. Governor Control System

1-23


Figure 1-11. Voltage Regulation System

1-13-5. DEAD CRANK Switch (5) . The DEAD CRANK switch is located in the engine compartment on the left side. Formaintenance purposes the switch allows the engine to be cranked without starting.

1-13-6. Engine (6). The generator is powered by a two cylinder, four cycle, fuel injected, naturally–aspirated, liquid–cooled diesel engine which occupies the front half of the generator set. The engine is also equipped with a fuel filter/waterseparator, oil filter, and an air cleaner assembly. Protection devices automatically stop the engine during conditions of highcoolant temperature, low oil pressure, no fuel, and overvoltage.

1-13-7. Batteries (7). Two batteries are required, one on each side of the generator set. The batteries are electrolyteserviceable, lead acid, 12 volt type, connected in series. After starting, the generator set is capable of operating with batter-ies removed. A fuse and a diode, located behind the control panel assembly, protects the generator set if the batteriesare incorrectly connected.

1-13-8. Water Pump (8). The water pump is located in the engine compartment on the front of the engine. The pumpcirculates the engine coolant through the engine block and the radiator.

1-13-9. Fuel Transfer Pump (9).The fuel transfer pump is located in the engine compartment on the front left side. Thepump is electrically operated and transfers fuel from the fuel tank to the engine through the fuel filter/water separator.

1-24


1-13-10 Auxiliary Fuel Pump (10). The auxiliary fuel pump is located behind the front housing panel on the left side.The pump is electrically operated and transfers fuel from an auxiliary fuel source to the fuel tank.

1-1-10.1. Auxiliary Fuel Filter (10A). The auxiliary fuel filter is located behind the front housing panel on the left side.The filter removes impurities from the diesel fuel when using the auxiliary fuel supply.

1-13-11. Radiator (11). The radiator is located at the front of the generator set. It acts as a heat exchanger for the enginecoolant.

1-13-12. Fuel Tank (12) . The 5 gallon (18.9 liters) fuel tank is located in the front of the generator set below the engineand between the skid base side members. The fuel tank is a fuel reservoir and has sufficient capacity to enable the genera-tor set to operate for at least 8 hours without refueling.

1-13-13. Air Cleaner Assembly (13). The air cleaner assembly is located on the right side behind the engine. It consistsof a dry-type, disposable air filter element made of paper and a canister. The air cleaner assembly features a dust collectorwhich traps large dust particles. The air cleaner assembly has a restriction indicator (visible by opening left engine accessdoor) which will indicate red when the air filter element requires servicing.

1-13-14. Muffler (14). The muffler and exhaust tubing are connected to the exhaust manifold on the engine. The exhaustexits from the top of the generator set housing. Gases are exhausted upward.

1-13-15. Fan Belt (15). The fan belt is located in the engine compartment on the front of the engine. The belt drives thefan, water pump, and the battery charging alternator.

1-13-16. Battery Charging Alternator (16).The battery charging alternator is located on the right side of the engine. Itis capable of maintaining the batteries in a state of full charge in addition to providing the required 24 VDC control power.

1-13-17. Start er (17). The starter is located on the right side of the engine. The electric starter mechanically engagesthe engine flywheel in order to start the diesel engine.

1-13-18. NATO SLAVE RECEPTACLE (18). The NATO SLAVE RECEPTACLE is located on the right side (rear) of thegenerator set. It is used for slave starting.

1-13-19. Skid Base (19). The skid base supports the generator set. It has fork lift access openings and cross membersfor short distance movement and lifting rings located at each corner of the skid base. The skid base has provisions in thebottom for installation of the generator set on a trailer.

1-13-20. Load Output Terminal Board (20). The load output terminal board is located on the bottom left side (rear) ofthe generator set. Four output terminals are located on the board. They are marked L1, L2, L3, and L0. A fifth terminal,marked GND, is located next to the output terminals and serves as equipment ground for the generator set. A removable,solid copper bar is connected between the L0 and GND terminals.

1-13-21. Load Output Terminal Board (21). The generator set control panel assembly is located at the rear of the generatorset and contains controls and instruments for operating the engine and the generator.

1-13-22. FREQUENCY ADJUST Control (22). The FREQUENCY ADJUST control is located at the rear left side of gen-erator set. It is used to adjust the generator frequency output.

1-13-23. Malfunction Indicator Panel (23). The malfunction indicator panel is located to the left of the control panel as-sembly. It indicates malfunctions of the generator set components.

1-13-24. CONVENIENCE RECEPTACLE (24). The CONVENIENCE RECEPTACLE is a 120 VAC receptacle used tooperate small plug in type equipment.

1-13-25. Diagnostic Connector (25). The diagnostic connector is a multi-pin plug that is wired to specific points in thegenerator set electrical system to enable monitoring and troubleshooting of the generator set operation at a single location.

Change 1 1-25


Figure 1-12. Generator Set Components

1-26 Change 1


CHAPTER 2

UNIT MAINTENANCE INSTRUCTIONS

Section I. SERVICE UPON RECEIPT OF EQUIPMENT

2-1. INSPECTING AND SERVICING THE EQUIPMENT.

This section provides information and guidance for inspecting, servicing, and installing the generator set under normalconditions.

2-1-1. Inspect ion.

a.

b.

c.

d.

e.

f.

g.

h.

i.

j.

k.

l.

m.

Unpack and inventory all end item components for serviceability.

Check that all packing materials have been removed.

Check generator set identification plate for positive identification.

Inspect generator set for any internal or exterior shipping damage.

Open engine compartment access doors and inspect batteries for damage.

Check battery cables for damage.

Open control panel access door and check panel for damage.

Lower control panel and check electrical connections for damage or loose connections.

Check air cleaner assembly and exhaust opening for obstruction.

Check fan drive belt for proper adjustment, paragraph 2-75-4.

Inspect generator set for loose or missing mounting hardware or damaged or missing parts.

Check oil level. Ensure that oil level is at FULL mark on dipstick If required, add engine lube oil specified inTable 2-3.

Unpack grounding rod, and auxiliary fuel hose. Inspect each item for damage.

2-1-2. Service.

2-1-2-1. Batteries.

For Battery service refer to TM9-6140-200-14

2-1-2-2. Radiator.

Do not operate generator set while servicing radiator. Damage to equipment orpersonal injuries may result.

a. Remove radiator cap

b. Check that radiator drain valve (Figure 1-12) is closed.

2-1


c.

d.

e.

f.

2-1-2-3.

Table 2-1. Coolant

AMBlENT TEMPERATURE RADIATOR COOLANT RATIO

+40°F TO +120°F WATER: MIL-A-53009 35:1(4°C TO 49°C) INHIBITOR, CORROSION

-25°F TO +120°F WATER: MIL-A-46153 1:1(-31°C TO 49°C) ANTIFREEZE

-25°F TO +120°F MIL-A-11755 N/A(-31°C TO 49°C) ANTIFREEZE

Fill radiator with proper coolant/antifreeze in accordance with Table 2-1. Fill radiator to a level two inches belowfiller neck opening. Cooling system capacity is 6.2 quarts (5.9 liters). Install radiator cap.

Remove overflow bottle cap.

Fill overflow bottle to COLD level and install overflow bottle cap.

Start generator set. After 30 minutes of operation, shutdown generator set and check coolant/antifreeze levelat overflow bottle. Add coolant/antifreeze in accordance with Table 2-1, to HOT level in overflow bottle.

Fuel Tank.

Maintain metal-to-metal contact between fuel tank filler neck and fuel nozzle toprevent sparks from static electricity. Do not smoke or use open frame in area offueling operation. Failure to follow this warning could result in explosion, severepersonal injury or death.

Table 2-2. Diesel Fuel

AMBlENT TEMPERATURE DIESEL FUEL

+20°F TO +120°F VV-F-800 GRADE DF-2,(-7°C TO 49°C) JP4, JP5, OR JP8

0°F TO +20°F VV-F-800 GRADE DF-1,(-17°C TO -7°C) JP4, JP5, OR JP8

-25°F TO 0°F VV-F-800 GRADE DF-1(-31°C TO -17°C)

-25°F TO 0°F VV-F-800 GRADE DF-A(-31°C TO -17°C)

2-2


a.

b.

c.

d.

2-1-2-4.

a.

b.

c.

d.

e.

f.

Hot refueling of generator set while operating presents a safety hazard andshould not be attempted. Hot engine surfaces and sparks produced from the en-gine and generator circuitry are possible sources of ignition. Severe injury ordeath could result.

Check that fuel drain valve (Figure 1-12) is closed.

Remove fuel tank filler cap.

Fill generator set fuel tank with fuel type specified in TABLE 2-2. Fuel capacity is 7.3 gallons (18.9 liters).

Install fuel tank filler cap.

Lubricating Oil.

Place suitable container under oil drain plug and remove plug.

Open left side engine access door. Open oil drain valve (Figure 1-12) and drain oil.

Close oil drain valve and remove oil fill cap.

Fill engine with proper lube oil in accordance with Table 2-3 to FULL mark on dipstick. Lubrication system ca-pacity is 3.2 quarts (3.0 liters).

Table 2-3. Lubricating Oil

AMBIENT TEMPERATURE LUBRICATING OIL

+20°F TO +120°F MIL-L-2104(-7°C TO 49°C) OE HDO-30 or OE HDO-

15/40

0°F TO +20°F MIL-L-2104(-17°C TO -7°C) OE HDO-10

-25°F TO 0°F MIL-L-46167(-31°C TO -17°C)

Install oil fill cap.

Close left side engine access door.

2-2. Generator Set Installation.

2-2-1. General.


a. Ensure that installation site is as level as possible.

b. Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set.

c. Place generator set within twenty-five feet (7.4 meters) of auxiliary fuel supply.

2-3


d. Refer to Figure 2–1 for minimum enclosure clearance measurement requirements and Figure 2–2 for basemounting measurements.

2-2-2. Outdoor Installation.

a. Make use of natural protective barriers.

b. Allow space on all sides for service and maintenance, refer to Figure 2–1.

c. Ensure that site soil is firm and well drained.

d. Use planks or other material for support in areas where soil will not support the generator set.

2-2-3. Indoor Installation.


2-4


Figure 2-1. Minimum Enclosure Clearance Measurements

2 - 5


Figure 2-2. Base Mounting Measurements

Never position generator set with the air inlets near a wall or other object that in-terferes with cooling air circulation. Damage to equipment could result.

a. Provide ducts and vents to outside of building if good supply of cooling air is not available,

b. Make air intake and outlet openings in building same size or larger as those on the generator set.

c. Install a gas tight metal pipe from exhaust pipe of generator set to outside of building.

NOTEMake exhaust pipe extension as short and straight as possible with only one 90 degreebend, if needed.

d. Ensure that inside diameter of exhaust pipe extension is as large or larger than generator set exhaust pipe.

Hot exhaust gases can ignite flammable materials. Failure to observe this warn-ing could result in severe personal injury or death.

e. Provide for harmless discharge of hot gases and sparks. Do not direct exhaust into area containing flammablematerials.

If not shielded, hot exhaust pipe can ignite flammable wall materials. Failure toobserve this warning could result in severe personal injury or death.

f . Shield exhaust pipe with fireproof material at point where it passes through a flammable wall.

2-6


An unwrapped exhaust pipe can cause injury if touched.

g. Wrap exhaust pipe in protective material.

2-3. FABRICATION/ASSEMBLY OF PARTS.

Table 2-4 is a list of generator parts that require fabrication or assembly when replacing. See Appendix D for fabricationand assembly instructions.

Table 2-4. Fabricated/Assembled Parts

NAME PART NUMBER

Cable Assembly, Battery 88–20312




Cable Assembly, Battery 88-20316

Cord, Load Wrench 88–22460

Diode Assembly 88-22418-1

Holder, Control Panel 88–20134

Insulation, Skid 88–20296

Pump Assembly, Fuel 88–20479

Pump Assembly, Fuel 88–22546

Solenoid Assembly, Fuel 88-20482

Transducer Assembly 88–20480

Wire, Varistor (L0) 88–20305-1

Wire, Varistor (L1) 86-20305-2

Wire, Varistor (L2) 88–20305–3

Wire, Varistor (L3) 88-20305-4

Section Il. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTICEQUIPMENT (TMDE); AND SPECIAL SUPPORT EQUIPMENT

2-4. REPAIR PARTS AND SPECIAL TOOLS LIST (R PSTL).

2-4-1. Tools and Equipment. There are no special tools or support equipment required to perform unit level maintenanceon the generator set. A list of recommended tools and support equipment required to maintain the generator set is con-tained in Appendix B, Section Ill.

2-4-2. Maintenance Repair Parts. Repair parts and equipment are listed and illustrated in the repair parts and specialtools list manual TM 9–6115–641–24P.

Section Ill. SPECIAL LUBRICATION INSTRUCTIONS

NOTEThere are no special lubrication instructions, refer to LO 9–6115–641–12 for generatorset lubrication requirements.

2-7


Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-5. PMCS PROCEDURES.

2-5-1. General. To ensure that the generator set is ready for operation at all times, it must be inspected so that defectscan be discovered and corrected before they result in serious damage or failure.

2-5-2. Puropse of PMCS TABLE.TABLE. Your Preventive Maintenance Checks and Services table lists the inspections and careof your equipment required to keep it in good operating condition.

2-5-3. Puropse of Service Intervals. The interval column of your PMCS table tells you when to do a certain check orservice.

2-5-4. Procedures Column. The procedures column of your PMCS table tells you how to do the required checks andservices. Carefully follow these instructions.

2-5–5. The “Equipment Is Not Ready/Available If”. This column tells you when and why the generator set cannot be used.

NOTEThe terms ready/available and mission capable refer to the same status: Generator setis on hand and is able to perform its combat missions (See DA PAM 738–750).

2-5-6. Reporting and Correcting Deficiencies. If your generator set does not perform as required, refer to Troubleshoot-ing section for possible problems. (A) Report any malfunctions or failures on DA Form 2404, or refer to DA PAM 738-750.(F) report any malfunctions or failures in accordance with applicable directives.

Table 2-5. Unit Preventive Maintenance Checks and Services

M–Monthly Q–Quarterly S-Semi–annually A–Annually B-Bi-annually H–Hours

ItemNo.

1

2

3

4

2-8

M Q

Interval

S

•

A

•

•

B

•

H

250

250

1500

Itemto be

Inspected

Engine LubeOil

Fuel Filter/WaterSeparatorElement

CoolingSystem

RadiatorCap

ProceduresCheck for and have

repaired oradjusted asnecessary

Drain engine lubeoil. Add properlube oil perLO 9–6115–641–12.

NOTE: Oil filtershould be changedwith lube oilchange. Refer toTM 9-281 5–252–24.

Change fuel filter/water separatorelement, Refer toparagraph 2-87.

Drain coolant andflush cooling system.Add proper coolant.Refer to paragraph2-69-2.

Inspect radiator cap forcorrosion, torn ordeteriorated seal, andobvious damaged.

Equipment isnot

Ready/AvailableIf:

Radiator cap or sealis damaged.


Table 2-5. Unit Preventive Maintenance Checks and Services - Continued

M-Monthly Q-Quarterly S-Semi-annually A-Annually B-Bi-annually H-Hours

ItemNo.

5

6

7

8

9

.

Interval

M Q S A

•

•

•

•

B HItemto be

Inspected

Air CleanerAssembly

Hardwareand soundInsulation

Radiator andInterior ofGeneratorSet

MagneticPickup



Remove batteries.Refer to paragraph2-12-2. Cleanbatteries, cableterminals, andbattery posts. Testbatteries for stateof charge. Refer toparagraph 2-12-1.

Inspect air cleanerassembly andmounting bracketfor cracks, dents, andother damage.Inspect element fordogs and damage.Clean or replace asnecessary. Cleanhousing with cleaningcloth.

Inspect for loose,damaged, or missinghardware and soundinsulation. Tightenloose hardware.Reapir or replacedamaged or missinghardware andinsulation.

Clean radiatorexterior surfaces.Refer to paragraph2-70-3. Cleanengine compartment.

Remove, inspect, anddean magneticpickup. Refer toparagraphs NO TAGand NO TAG.

Equipment isnot

Ready/AvailableIf:

Batteries will nothold charge.

Loose, missing,or damagedhardware orinsulation.

Magnetic pickup isdamaged.

2-9

Batteries


Table 2-5. Unit Preventive Maintenance Checks and Services - Continued

M-Monthly Q-Quarterly S-Semi-annually A–Annually B-Bi-annualIy H-Hours

ItemNo.

10

11

12

M Q

Interval

s A

•

Ž

•

B H

500

Secti

Itemto be

lnspected

WiringHarnesses

Muffler

Auxiliary Fuel Fil-ter

on V. TROUBLES



Inspect wiringharnesses forbreaks and looseconnections. Repairand tighten wiringharnesses asnecessary.

Check muffler forleaks, restriction, andaccumulation ofcarbon. Replace orclean as required.

NOTEIf the auxiliary fuel sys-tem is used as the pri-mary fuel source, thenthe auxiliary fuel filtermust be replaced semi-annually.

Check for proper opera-tion using the auxiliaryfuel system as primarysource.

HOOTING

Equipment isnot

Ready/AvailableIf:

Wiringharnesses aredamaged orconnections areloose.

Muffler leaks, isrestricted, or hasexcessive carbonaccumulation.

2-6-1. Purpose of Troubleshooting TABLE. This section contains troubleshooting information for locating and correctingoperating troubles which may develop in the generator set. Each malfunction for an individual component, unit, or systemis followed by a list of test

TM 9-6115-641-24Title TM 9-6115-641-24 Author US Army Subject Unit, Direct & General Support for...

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Transcript of TM 9-6115-641-24Title TM 9-6115-641-24 Author US Army Subject Unit, Direct & General Support for...